Fluid Quality Monitoring and Filtration System

ABSTRACT

A fluid filtration system may include a fluid filter assembly that includes a filter element configured to filter a fluid and a sensor probe incorporated into the fluid filter assembly. The sensor probe may include a chemically reactive material sensitive to at least one property of the fluid and at least a portion of the sensor probe may be exposed to the fluid.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims priority to and the benefit of U.S. ProvisionalPatent Application No. 61/838,962, filed Jun. 25, 2013, the entiredisclosure of which is incorporated herein by reference.

FIELD

This technical disclosure relates to monitoring fluid quality in a fluidfiltration system.

BACKGROUND

Oil drain intervals for internal combustion engines are determined byengine manufacturers through rigorous testing. However, a manufacturercannot simulate all the conditions under which an engine can subject thelubricating oil to. Determining the quality of the in-servicelubricating oil in-situ would provide a more accurate assessment of whenthe oil should be changed. In addition to assessing quality, assessingoil chemical constituents of the in-service lubricating oil in-situwould be useful.

Similarly, the reliability and/or performance of high pressure commonrail diesel fuel injection systems may be adversely impacted by thepresence of certain contaminants in the fuel, such as water. Typically,the end user would not be aware of the presence of these contaminantsuntil engine performance has been impacted. As such, the ability todetect the presence of contaminants and advise the operator or servicepersonnel accordingly is desirable.

A polymeric bead matrix (PBM) sensor probe is a known type of sensorused to sense the quality of a fluid such as oil. Examples of PBM sensorprobes and how they work are described in U.S. Pat. Nos. 5,435,170;5,777,210; 5,789,665; 7,521,945; and 7,928,741. It is known to use PBMsensors on oil sumps in engines.

SUMMARY

Various embodiments provide a system and method wherein a disposablesensor probe is incorporated into a fluid filter assembly, including butnot limited to a lubrication oil, hydraulic fluid or fuel filterassembly. The sensor probe can be designed to sense the quality of thein-service fluid in-situ, and also can provide the ability to assesschemical or contaminant constituents of the fluid thereby providinginformation that can be used to, for example, to determine fluid orfilter service intervals.

The fluid can be any fluid that one wishes to monitor the quality ofincluding, but not limited to, oils such as lubrication oil, hydraulicfluid, turbine oil, gear oil, compressor oil, transformer oil, fuel suchas diesel fuel, water, engine coolant, glycol and amine-based fluids andester-based fluids, and other liquids. The fluid can be used in anengine, for example a diesel engine, a hydraulic system, or in any otherfluid system.

The sensor probe can be suitably integrated into a fluid filtrationsystem having a fluid filter assembly that includes a disposable filterelement. In one embodiment, the sensor probe can be integrated orinstalled into the fluid filter assembly, such as the disposable filterelement, the filter head, a filter housing, a standpipe, the sump, anengine lubricating fluid circuit, or other filter components. Accordingto another embodiment, the sensor probe may be incorporated into acentrifuge cartridge. The sensor probe can be in electricalcommunication, wired or wirelessly, with a suitable controller, such asan engine control module/unit (ECU) or other device utilizing a signalprocessor, which in turn provides an output indicative of the quality ofthe fluid being filtered.

In one embodiment, the sensor probe can be integrated into thedisposable filter element, such as a lube oil, hydraulic fluid, turbineoil, gear oil, compressor oil, or fuel filter element. When the sensorprobe is an integral part of the disposable filter element, replacementof the sensor probe can be simply accomplished by changing the filterelement.

In one embodiment, the sensor probe can be integrated into otherelements of the fluid filter assembly such as the filter head, thehousing, the standpipe, or other filter components. In this embodiment,replacement of the sensor probe may be a separate action from servicingof the disposable filter element, but may occur at the same time thatthe disposable filter element is serviced.

A sensor probe as used in this disclosure and claims is defined, unlessotherwise indicated by the applicant, as any type of sensing device thatemploys chemically reactive material(s) and may therefore be sensitiveto certain properties (e.g. a chemical concentration, a contaminantconcentration, or a fluid parameter) of the fluid being filtered. Forexample, at least one electrical property of the chemically reactivematerial(s) may temporarily or permanently change upon exposure tocertain properties, such as a chemical or contaminant species ofinterest, of the fluid being monitored. The changes in the electricalproperty may indicate at least one of the fluid quality, the fluidchemistry, or the chemical composition of the fluid. According to oneembodiment, the sensor probe may return to its base condition after aperiod of time or after certain processing. One example of a sensorprobe that can be used includes, but is not limited to, a PBM sensorprobe that employs chemically reactive polymeric bead(s) disposed in aspace between two electrodes, such as an inner and an outer electrode.The PBM sensor probe can have a construction as described herein, ordescribed in U.S. Pat. Nos. 5,435,170; 5,777,210; 5,789,665; 7,521,945;and 7,928,741, or other constructions employing chemically reactivepolymeric beads and that are capable of sensing fluid quality and/orassess chemical constituents of the fluid. Alternatively oradditionally, the sensor probe may use an inorganic or non-polymericmaterial, such as zeolite, that may respond to changes in fluid qualityand/or chemical constituents.

Fluid quality, as the term is used in this disclosure and claims, isdefined, unless otherwise indicated by the applicant, as any property orparameter or combination of parameters or properties of a fluid beingmonitored that is measurable by the sensor probe as a result of atemporary or permanent change in the electrical properties of the sensorprobe upon exposure to certain properties, such as the chemical orcontaminant species of interest, of the fluid being monitored orfiltered. In the case of lube oil applications, one example of fluidquality includes, but is not limited to, the oil acidity or a specificoil additive. In the case of fuel applications, one example of fluidquality includes, but is not limited to, the concentration of water orsulfur in the fuel. Alternatively or additionally, the fluid quality mayinclude at least one of a soot level, fuel concentration, waterconcentration, or an extent of at least one of additive depletion, fluidoxidation, nitration, thermal degradation, liquid contamination, solidcontamination, or semi-solid particulate contamination.

A single sensor probe or multiple sensor probes can be provided. Thesingle sensor probe can be designed to sense a single qualitycharacteristic or chemical constituent of the fluid, or the sensor probecan be designed to sense a plurality of quality characteristics and/orchemical constituents of the fluid. If multiple sensor probes are used,each probe can sense a different quality characteristic or chemicalconstituent of the fluid or one or more of the probes can be designed tosense a plurality of quality characteristics and/or chemicalconstituents.

In the case of lube oil, many oil quality monitoring and sensingtechnologies can be intended to last the life of the engine. As such,they tend to be more expensive and outlast the typical service intervalof a fluid filter. On the other hand, a sensing probe described hereincan provide more data with regards to more specific oil qualitymeasures. According to one embodiment, the sensing probe may bedisposable and may undergo a permanent change in its electricalproperties. Thus, the sensor probe may be regularly replaced with, forexample, the filter element or when an oil change occurs, and the sensorprobe may further provide more useful fluid quality data at a low cost.According to one embodiment, the sensor probe must be replaced with thefilter element due to the configuration and properties of conventionalsensor probes.

In addition, by having the sensor probe installed with the filterelement, the sensor probe may be changed at each oil change and/or whenthe filter is changed. With the current technology platforms, both theoil sensor and filter may be changed independently, requiring multiplemaintenance steps in replacing the consumable components. With thesensor probe described herein installed with the filter element, themultiple maintenance steps can be reduced to a single maintenance stepcreating a more efficient maintenance procedure. Additionally, theconsumer may only have to purchase one replaceable part (i.e. the filterelement and integrated sensor probe), rather than multiple replacementparts at each oil change.

The result of having a single consumable part (e.g. the filter elementand the integrated sensor probe) has an additional advantage in thedesign and cost of the sensor probe and ensures that the sensor probe isreplaced. If the sensor probe were to remain separate from the oilfilter element, then the potential oversight of maintenance workers toreplace the probe during an oil change would require that the probe bestructurally designed to withstand the resulting increased service lifeof the sensing probe. Additionally, the oil quality monitoring systemmay become unreliable if the probe is not replaced each oil maintenanceinterval. However, by integrating the sensor probe with the filterelement (thus ensuring changing at each maintenance interval), thedesign of the sensor probe can be optimized for the decreased in-servicelife, which may result in a decreased material and manufacturing cost ofthe probe. Also, integrating the sensor probe with the filter elementmay ensure that the sensor probe's impact on the fluid qualitymonitoring system's reliability is enhanced.

In addition to the previously discussed advantages, integrating thesensor probe with the disposable filter element can further provide ameans of protecting engines and equipment by ensuring that appropriatefiltration is being used. Filter elements that lack the integratedsensor probe may not produce a recognizable electrical signal to thecontroller, enabling recognition that an inappropriate filter element isbeing used. This could be used to alert the operator accordingly or toadapt the fluid quality diagnostics for operation in a mode to mitigatedamage to the engine caused by improper filtration.

Various embodiments provide for a fluid filtration system including afluid filter assembly that includes a filter element configured tofilter a fluid and a sensor probe incorporated into the fluid filterassembly. The sensor probe may include a chemically reactive materialsensitive to at least one property of the fluid and at least a portionof the sensor probe may be exposed to the fluid.

Another embodiment provides for a filter element that may includefiltration media suitable for filtering a fluid and a sensor probearranged relative to the filtration media so as to be in contact withthe fluid prior to or after being filtered by the filtration media. Thesensor probe may include a chemically reactive material whose electricalproperties change according to at least one property of the fluid, andthe sensor probe may be disposable with the filtration media. The sensorprobe may also include identifying information regarding the filterelement.

Yet another embodiment provides a method of monitoring a fluid within afluid filter assembly. The method may include integrating a sensor probeinto a filter element of the fluid filter assembly and exposing thesensor probe to the fluid. The sensor probe may include a chemicallyreactive material whose electrical properties change as a result of atleast one property of the fluid being filtered.

These and other features (including, but not limited to, retainingfeatures and/or viewing features), together with the organization andmanner of operation thereof, will become apparent from the followingdetailed description when taken in conjunction with the accompanyingdrawings, wherein like elements have like numerals throughout theseveral drawings described below.

DRAWINGS

FIG. 1 is a schematic depiction of a fluid filtration system thatincorporates a disposable sensor probe according to one embodiment.

FIG. 2 is a simplified schematic cross-sectional view of one embodimentof a sensor probe that can be used.

FIG. 3 illustrates the sensor probe of FIG. 2 incorporated into acartridge filter element according to one embodiment.

FIG. 4 illustrates a sensor probe incorporated into one embodiment of aspin-on filter element.

FIG. 5 illustrates a sensor probe incorporated into another embodimentof a spin-on filter element.

FIG. 6 is a schematic representation showing a sensor probe integratedinto the filter assembly according to yet another embodiment.

DETAILED DESCRIPTION

As described further below and referring to the figures generally, thevarious embodiments disclosed herein related to systems and methodswhere a sensor probe may be incorporated into a fluid filter assembly.The sensor probe may sense the quality of the in-service fluid in-situ,and may also assess the chemical constituents of the fluid therebyproviding information that can be used to, for example, tailor chemicaladditives to be added to the fluid and/or to determine when it is timeto service the filter and/or the fluid.

A fluid filtration system is defined herein as a system that includesthe fluid filter assembly and other components such as fluid flow linesand an engine or other system that utilizes the fluid.

The fluid filter assembly can be any assembly that is used to filter afluid including, but not limited to, a lubrication oil, hydraulic fluid,or fuel filter assembly. The fluid can be any fluid that one wishes tomonitor the quality of including, but not limited to, lubrication oil,hydraulic fluid and fuel such as diesel fuel. The fluid can be used inan engine, for example a diesel engine, a hydraulic system, or in anyother fluid system.

A fluid filter assembly is defined herein as including a disposablefilter element, a filter head to which the disposable filter element isattached, a filter housing, an optional standpipe that is part of thefilter housing and over which the disposable filter element isinstalled, or optional additional filter components. The fluid filterassembly may be, for example, a cartridge-style filter in which thefilter element (or filter element cartridge) may be removed from thefilter housing and replaced separately from the filter housing.Alternatively, the fluid filter assembly may be, for example, a spin-onfilter (as shown in FIGS. 4 and 5) in which the filter housing maycontain the filter element and both the filter housing and element maybe removed, disposed of, and replaced at the same time. Accordingly, thedisposable filter element can be, for example, a disposable filterelement cartridge that is removably installed within a filter housingduring use, or a disposable spin-on type filter element where the filtermedia is disposed within a filter housing and the filter media andfilter housing are disposed of together.

A filter element is defined herein as any disposable filter suitable forfiltering a fluid, where the disposable filtration media has an upstreamor unfiltered fluid side and a downstream or filtered fluid side. Thefilter element may use, for example, filtration media or a fibrousmaterial to remove at least one contaminant. The filter element mayoptionally include at least one endcap, a center tube, a housing, and/ora nutplate. The fluid to be filtered flows from the upstream side to thedownstream side through the filtration media which filters the fluid.The filtration media can be arranged in any configuration including, butnot limited to, a ring or a panel. The filtration media can be removablefrom a filter housing and disposed of, such as cartridge filterelements. The filtration media can also be disposed (optionally)permanently, within a housing, where both the filtration media and thehousing are disposed of, such as in a spin-on filter element.

The sensor probe can be suitably integrated anywhere in the fluidfiltration system. In one embodiment described in detail below, thesensor probe is integrated into the fluid filter assembly, particularlythe disposable filter element. When the sensor probe is an integral partof the disposable filter element, replacement of the sensor probe issimply accomplished by changing the filter element, which may, accordingto various embodiments, be attached to other components within the fluidfilter assembly. However, the sensor probe may be integrated into otherelements of the fluid filter assembly, such as the filter head, thehousing, the standpipe, the nutplate, the filter housing, or othernon-filter element or filter components. Therefore, the sensor probe maybe replaced separately from servicing the disposable filter element.Replacing the sensor probe may optionally occur at the same time thedisposable filter element is serviced.

According to another embodiment, the sensor probe may be incorporatedinto a centrifuge cartridge. For example, the sensor probe may beintegrated with centrifuges commonly known as “ConeStaC™” or “SpiraTec™”centrifuges, which may be disposable or incinerable. The ConeStaC™centrifuge may allow fluid flow to pass through gaps between a conestack, which may reduce the distance for the particles to travel to becaptured and may therefore increase efficiency. The SpiraTec™ centrifugeor rotor may increase the separation efficiency by reducing the distancethe contaminated fluid must travel within the rotor before separatingand sending clean oil back to the sump. More specifically, theSpiraTecTM centrifuge may allow fluid to pass through gaps betweenspiral vanes, which guide the contamination outward to the rotorperimeter where the G-forces are highest. The contamination may collecton the inside rotor wall.

The sensor probe may be situated upstream or downstream of the filterelement. For example, a sensor probe that is downstream of the filtermedia may indicate that a fuel-water separator has failed. Alternativelyor additionally, a sensor probe located upstream of the filter media mayindicated that the operator has received a shipment of poor quality fuel(e.g. fuel containing excessive amounts of water).

FIG. 1 is a schematic depiction of a fluid filtration system 10 thatincorporates a disposable sensor probe 12. In the illustrated example,the system 10 is shown as being part of an engine or hydraulic system 14and supplies a fluid, such as lube oil, fuel or hydraulic fluid to theengine or hydraulic system 14 along fluid flow lines 16. In thisexample, the sensor probe 12 is shown as being integrated into a fluidfilter assembly 18 that is fluidly connected in the flow lines 16 tofilter the fluid flowing through the flow lines before the fluid isdirected to the engine or hydraulic system 14.

In the case of lubrication and hydraulic systems, the lube oil orhydraulic fluid is recirculated in a closed flow path. In a fuel system,typically some of the fuel is burned in the combustion process as shownby the dashed line 20 and some fuel is recirculated. The sensor probe 12produces an electronic output or electrically communicates, via wires orwirelessly, with a suitable controller 22 (as shown by dashed line 26),such as an engine control module/unit (ECU) or other signal processor,which in turn provides some form of an indicator or output 24 indicativeof the quality of the fluid being filtered (which may be transmittedthrough a variety of means and is shown with dashed line 28). The output24 can be in any form including, but not limited to, a visual signal, anaudible signal, a numerical value, an indicator on a gauge, acontrolled, automatic release of additive into the fluid, and anycombination thereof.

The sensor probe 12 can be any type of sensing device that employschemically reactive material(s) whose electrical properties maytemporarily or permanently change upon exposure to a property, such as achemical or contaminant species or element of interest, in the fluidbeing monitored. According to one embodiment, the sensor probe mayreturn to its base condition after a period of time or after certainprocessing. According to one embodiment, in the case of the fluid beinglubrication oil and where one is interested in monitoring the acidity ofthe oil or a specific oil additive, the electrical properties ofchemically reactive material(s) in the sensor probe may undergo atemporary or permanent change when exposed to the acids or the oiladditive, if present in the oil. Similarly, according to anotherembodiment in the case of the fluid being fuel and where one isinterested in monitoring the concentration of water in the fuel, theelectrical properties of chemically reactive material(s) in the sensorprobe may undergo a temporary or permanent change when exposed to thewater, if present in the fuel. The change in the electrical propertiesof the sensor probe 12 may be communicated to the controller 22.

According to another embodiment, the sensor probe 12 may include a PBMsensor probe that employs chemically reactive polymeric bead(s) disposedin a space between two electrodes, such as an inner and an outerelectrode. Instead of or in addition to polymeric beads, water absorbinghydrogels, zeolties, silica, or other inorganic or non-polymericmaterial that responds to specific chemical changes, species, orelements may be used. For example, the polymeric beads could be replacedby a superabsorbent hydrogel, silica or clay in order to detect water infuel. A schematic depiction of the basic features of a PBM sensor probethat can be used is shown in FIG. 2. The PBM sensor probe can haveconstructions other than that shown in FIG. 2. Additional information onthe construction and operation of PBM sensor probes can be found in U.S.Pat. Nos. 5,435,170; 5,777,210; 5,789,665; 7,521,945; and 7,928,741,which are incorporated herein by reference in their entirety. However,sensor probes other than PBM sensor probes can be used.

In FIG. 2, the probe 12 is generally cylindrical in construction andincludes two sensing chambers 30 a, 30 b making up the sensing portionof the probe. In the first or upper chamber 30 a, a space 32 is definedbetween a first perforated, cylindrical outer electrode 34 and a firstinner or central electrode 36 that is surrounded by the electrode 34. Inuse, the PBM sensor probe may be connected to the fluid filtrationsystem such that the fluid can at least partially fill the space 32, andthe conductance or polarity of the fluid filled space 32 between theelectrode 34 and the electrode 36 is measured.

In the second or lower chamber 30 b, a space 38 is defined between asecond perforated, cylindrical outer electrode 40 and a second inner orcentral electrode 42. The electrode 42 could be separate from theelectrode 36, or the electrodes 42 and 36 can be integrally formed witheach other. Polymeric beads 44 may fill the space 38. In use, the fluidfills the voids between the polymeric beads 44 in space 38, and theconductance or polarity of the fluid and polymeric bead filled space 38between the electrode 40 and the electrode 42 is measured.

According to another embodiment, the sensor probe 12 may condition andcompare the signals or conductance of the electrodes and the controller22 may not be required to measure the conductance.

The two chambers 30 a, 30 b may be separated by an insulator 46, and aninsulator 48 may be disposed between the chamber 30 b and a mountingprotrusion 50 that aids in mounting the PBM sensor probe. The variouselectrodes 34, 36, 40, 42 are electrically connected via wires or othermeans to electrical connectors 52 in the mounting protrusion forelectrically connecting the PBM sensor probe to the controller 22. Allof the components are housed within a housing 54. The probe 12 may alsobe configured to allow fluid to penetrate into the interior spaces 32,38. For example, this can be achieved by making some or all of thehousing 54 permeable to the fluid, such as by providing perforations inat least the upper portion of the housing 54 or making the material thatforms the upper portion of the housing 54 generally freely permeable tothe fluid. Fluid may also be allowed to flow in and/or out via the uppertip end of the probe 12, such as through a permeable or aperturedstructure at the upper tip end. In such cases, it may also be desirablefor insulator 46 to be a permeable or apertured structure to facilitatefluid entry to chamber 30 b.

By comparing at least one of the conductivity or capacitance across thetwo chambers 30 a, 30 b, a characteristic of the fluid or fluid qualityparameter can be determined. Alternatively or additionally, at least oneof the conductivity or capacitance across one of the chambers 30 a or 30b may be used as a fluid quality parameter. The electrical properties ofthe polymeric beads 44 may temporarily or permanently change when thebeads 44 are exposed to the requisite chemical or contaminantconstituents of interest present in the fluid being monitored. Thedifferential conductivity (or capacitance) between the two or morechambers 30 a, 30 b may be indicative of the condition of the fluid.This can be used to determine when to change the fluid, sensor andfilter, for recirculating fluid systems such as lube or hydraulic oilsystems. For fuel systems, this can be used to prompt corrective actionby service or other personnel, such as changing the filter and sensor,the addition of fuel additives to the fuel, etc.

The sensor probe 12 can be formed with multiple chambers containingpolymeric beads or other sensing materials that respond to differentchemical or contaminant constituents or that are shielded from exposureto certain chemical or contaminant species in the fluid. This wouldenable the sensor probe to monitor different properties of the fluid.Alternatively, multiple sensor probes 12 can be provided, each of whichis designed to monitor different chemical or contaminant species ordifferent properties of the fluid

In the example illustrated in FIG. 2, the outer electrode 34 can beintegrally formed with the outer electrode 40 so that they form asingle, unitary, one-piece construction, and/or the electrode 36 can beintegrally formed with the electrode 42 so that they form a single,unitary, one-piece construction. However, the electrodes can be formedseparately from one another. Further, if the two pairs of electrodes(e.g. electrode 34 and 40 and/or electrodes 36 and 42) each form asingle, unitary, one-piece construction, the two pairs of electrodes maybe electrically isolated from one another and measured separately.

As discussed above, it may be advantageous to integrate the sensor probe12 into the disposable filter element because replacement of the sensorprobe may be accomplished by changing the filter element. The sensorprobe 12 can be integrated into any type and form of disposable filterelement.

FIG. 3 illustrates an example where the sensor probe 12 may beincorporated into a disposable filter element cartridge 60 that in useis removably disposed inside of a filter housing (not shown). Thecartridge 60 together with the sensor probe 12 can be removed from thefilter housing and replaced with a new cartridge containing the sensorprobe.

The cartridge 60 can have many configurations depending upon itsapplication. In the illustrated example, the cartridge 60 includes aclosed loop of pleated filter media 62, generally cylindrical in shape,having a first axial end 64 and a second axial end 66 and defining ahollow interior space 67. At the first axial end 64 is an open endplate68 that can be, for example, annular in shape and bonded to the end 64of the media 62 using an appropriate adhesive or thermally bonded to themedia. A hole 70 in the center of the endplate 68 enables fluid flow outof or into the interior space 67. The endplate 68 may provide structuralsupport for the pleated filter media 62 and may seal at least one of theends of the pleated filter media 62. Alternatively or additionally, theendplate 68 may provide a sealing surface for the filter cartridge to afilter head (not shown) or to the rest of the filter assembly. Theendplate 68 may or may not include a compressible gasket or othersealing material to affect a seal. If the endplate 68 does not include agasket or other sealing material, a gasket or other sealing material maybe part of the corresponding mating housing/head structure.

A second, closed endplate 72 may be attached to the second axial end 66of the media 62. The endplate 72 may be generally similar to theendplate 68, except that it lacks a flow hole. However, the endplate 72may include a hole in which the sensor probe 12 is mounted and sealed tothe endplate 72. The sensor probe 12 may protrude into the hollowinterior space 67 where it is positioned to detect and measure theproperties of the fluid. The electrical connector and the mountingprotrusion 50 may protrude away from the endplate 72 in the oppositedirection. The protrusion 50 may be of any design that enables thesensor probe 12 to communicate (directly via wires or indirectly usingwireless communications) to the controller 22 such as an ECU or othersignal processing or analysis unit. Examples of such connections arewell known, such as those commonly used in the industry to connectwater-in-fuel sensors used with fuel water separators to an engine'sECU. The protrusion 50 can further help to properly position the sensorprobe 12 within the filter housing to ensure both proper sealing andelectrical connection. An optional perforated center tube 74 can also beused that extends from the endplate 68 to the endplate 72 and thatsurrounds the interior cavity 67 to provide additional support, strengthand rigidity to the media 62.

FIG. 4 illustrates an example where the sensor probe 12 may beincorporated into a disposable spin-on filter element 80 known in theart. The spin-on filter element 80 may include a filter cartridge 82enclosed within a disposable shell or housing 84 that is open on oneend. The open end may be closed by a threaded nutplate 86 with a centralhole or opening 88 for fluid flow and typically a series of holesarranged annularly around the central hole for fluid flow in the reversedirection. The threaded nutplate 86 may be used to attach the spin-onfilter to the mounting spud on the filter head. Gaskets or other sealingmeans may be used to seal the filter cartridge to the nutplate 86 and toensure that the flow of fluid is directed through the filter media 90.Similar to the cartridge 60 in FIG. 3, the cartridge 82 may include anopen endplate 92 at one end and an endplate 94 at the other end. In thisexample, a means 96 for introducing an additive into the fluid may bedisposed between the endplate 94 and the closed end of the housing 84. Aspring 98 may abut a bottom endplate 74 in order to bias the filtercartridge 82 against the nutplate 86. Further information on one type ofspin-on filter element construction can be found in U.S. Pat. No.5,906,736, the filter of which may include a funnel or venturi tube, orU.S. Pat. No. 7,510,653, the filter of which may be an additive releasefilter.

In FIG. 4, the sensing portion of the sensor probe 12 is illustrated asbeing disposed in an interior space of the housing 84 between the end ofthe filter cartridge 82 and the closed end of the housing 84, on theupstream side of the filter media to sense the fluid before the fluid isfiltered. The sensor probe 12 may be secured to the closed end of thehousing 84 in a manner that seals and does not leak and enableselectrical connection to the controller 22 as discussed above for FIG.3.

FIG. 5 illustrates another embodiment of a disposable spin-on filterelement 100 known in the art that is modified to integrate the sensorprobe 12. In this embodiment, the sensing portion of the sensor probe 12may be positioned inside an interior space 102 of the filter mediacylinder 104 similar to the embodiment shown in FIG. 3 on the downstreamside of the filter media to sense the fluid after the fluid has beenfiltered. Similar to the cartridge 60 in FIG. 3, the cartridge mayinclude an open endplate 106 at one end and a closed endplate 108 at theother end. In this embodiment, a coil spring 110 may act directlyagainst the filter cartridge to bias the cartridge against the nutplate.

In lube and hydraulic oil applications, as oil degrades, the sensorprobe 12 may produce an electronic output that can be utilized by thecontroller 22 to provide a real-time assessment of the oil quality. Asthe oil quality deteriorates, the chemically reactive material(s) of thesensor probe 12 undergoes reversible or irreversible chemical change ifexposed to the chemical or contaminant specie(s) it is designed tomonitor, which changes its electrical properties and thereby changes theelectrical output of the sensor probe. (According to one embodiment, thesensor probe 12 may return to its base condition after a period of timeor after certain processing.) At a predetermined threshold, both theprobe 12 and the oil may be replaced as the probe 12 may no longer beusable for its intended purpose and the oil quality has degraded below apredetermined threshold. At the same time, the filter may also bereplaced. Since the sensor probe 12 is part of the disposable filterelement, the sensor probe may be replaced during each oil change alongwith the filter element. This ensures that spent sensor probes arereplaced as required. An advantage of the sensor probe described hereinis that it may not require recalibration, reinitialization, or a resetof the oil quality monitoring system when the sensor probe is replaced.Further, the cost, size and replaceable nature of the sensor probesfacilitate their integration into the disposable filter element,enabling both disposable items (e.g. the filter element and the sensorprobe) to be replaced simultaneously.

In fuel applications, much of the fuel is burned during combustionrather than recirculated. As a result, the properties of the fluid mayvary due to the regular addition of new fluid (which may potentiallyhave different properties). However, the comparison between theconductances across the two chambers 30 a, 30 b may dampen, lessen, oreliminate these fluctuations, allowing the critical species and/orparameters to be detected. In the case of water, the sensor probe maydetect water concentration in the fuel.

According to another embodiment, the fluid filtration system may includea viscosity sensor for a more completely measure of the quality of thelubricant. The viscosity sensor may also produce an electronic output toprovide real-time assessment of the oil quality (more specifically, ofthe oil viscosity). The viscosity sensor may be disposable ornon-disposable. Further, the viscosity sensor may be positionedseparately from the sensor probe or may be integral with the sensorprobe. The viscosity sensor may be upstream or downstream from thefilter element.

According to another embodiment, the sensor probe can be used to ensurethat the correct filter is installed and/or to provide the broaderengine system information concerning the filter. In this context, thesensor probe may be particularly useful when replacing, servicing, orrepairing the filter in order to prevent an incorrect filter beinginstalled within the fluid filtration system. Information from thesensor probe (which may be stored, for example, on an integrated circuit(IC) or a memory chip embedded therein) may be used by the enginecontrol module (ECM) to identify or recognize the installed filter,shell, etc. based on electronic output of the sensor.

FIG. 6 is a schematic representation showing a sensor probe 112integrated into a filter assembly 118 according to this furtherembodiment. The sensor probe 112 includes a data storage and/or dataprocessing unit 114 which may comprise an IC or memory chip embeddedinto the sensor probe 112. The data storage and/or data processing unit114 may contain the details or the identity of the filter (e.g. a filteridentification number, a filter batch number, etc.), information such asfilter media's characteristics, and other information about the filter.The data storage and/or data processing unit 114 may also containsoftware or algorithms to process the raw data from the sensor probe 112so as to indicate the quality of the fluid being filtered. This data maythen be communicated to the engine control module (ECM) 116 via wires orwirelessly (as shown by dashed lines 115). This information can then beanalyzed by the ECM to confirm if the filter is genuine and (ifappropriate) to provide an indication 120 if the filter is not genuine.

It should be noted that the use of the sensor probe to provideidentification information may be implemented independently of thechemically reactive material in certain embodiments. In other words, itis possible for identifying information to be provided in conjunctionwith the sensor probe without any fluid-sensitive chemically reactivematerials being included anywhere on the filter.

In the situation where the sensor probe includes identifying informationabout the filter, the ECM may analyze this information in variouscontexts. For example, the ECM may use the identifying information toconfirm that the correct or OEM-approved filter has been installed.Alternatively or additionally, the ECM could use the identifyinginformation to determine the type of filter being used and, in responseto this information, the ECM adjust the operation of the engine systemas appropriate.

Still further, the very existence (or non-existence) of the sensor probecan be an indication of information concerning the appropriateness ofthe filter. In a particular arrangement, for example, the ECM canattempt to locate and identify the filter element based upon theexpected information of the sensor probe. If the sensor probe is notpresent, then the ECM would recognize that the proper filter is notpresent. In response thereto, the ECM may communicate an indication 120that the filter is not genuine. This indication 120 can be used toprevent the engine from operating, or otherwise restrict or limit thescope of the engine's operation, in order to reduce or prevent potentialdamage to the engine and associated components and systems.

The invention may be embodied in other forms without departing from thespirit or novel characteristics thereof. The embodiments disclosed inthis application are to be considered in all respects as illustrativeand not limitative. The scope of the invention is indicated by theappended claims rather than by the foregoing description; and allchanges which come within the meaning and range of equivalency of theclaims are intended to be embraced therein.

It is anticipated that the various components, configurations, andfeatures of the different embodiments of the sensor probe 12 may becombined according to the desired use and configuration.

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” etc.) are merely used to describe the orientation ofvarious elements in the FIGURES. It should be noted that the orientationof various elements may differ according to other exemplary embodiments,and that such variations are intended to be encompassed by the presentdisclosure.

It is important to note that the construction and arrangement of thevarious exemplary embodiments are illustrative only. Although only a fewembodiments have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Forexample, elements shown as integrally formed may be constructed ofmultiple parts or elements, the position of elements may be reversed orotherwise varied, and the nature or number of discrete elements orpositions may be altered or varied. The order or sequence of any processor method steps may be varied or re-sequenced according to alternativeembodiments. Other substitutions, modifications, changes and omissionsmay also be made in the design, operating conditions and arrangement ofthe various exemplary embodiments without departing from the scope ofthe present invention.

1-17. (canceled)
 18. A filter element, comprising: filtration mediasuitable for filtering a fluid; and a sensor probe arranged relative tothe filtration media so as to be in contact with the fluid prior to orafter being filtered by the filtration media, the sensor probe mountedto an endplate attached to an axial end of the filter media, the sensorprobe includes a chemically reactive material whose electricalproperties change according to at least one property of the fluid, andthe sensor probe is disposable with the filtration media.
 19. The filterelement of claim 18, wherein the filtration media comprises a disposablering of filtration media, having a first end and a second end andcircumscribing a central cavity.
 20. The filter element of claim 18,wherein the at least one property includes at least one of a chemicalconcentration, a contaminant concentration, or a fluid parameter. 21.The filter element of claim 18, wherein changes in the electricalproperties indicate at least one of a fluid quality, a fluid chemistry,or a chemical composition of the fluid.
 22. The filter element of claim21, wherein the fluid quality includes at least one of a soot level,fuel concentration, water concentration, or an extent of at least one ofadditive depletion, fluid oxidation, nitration, thermal degradation,liquid contamination, solid contamination, viscosity, or semi-solidparticulate contamination.
 23. A method of monitoring a fluid within afluid filter assembly, comprising: integrating a sensor probe into afilter element of the fluid filter assembly by mounting the sensor probeto an endplate of the filter element, wherein the sensor probe includesa chemically reactive material whose electrical properties change as aresult of at least one property of the fluid being filtered; andexposing the sensor probe to the fluid.
 24. The method of claim 23,wherein the at least one property includes at least one of a chemicalconcentration, a contaminant concentration, or a fluid parameter. 25.The method of claim 23, further comprising measuring electrical changesin the electrical properties.
 26. The method of claim 23, wherein theelectrical changes indicate at least one of a fluid quality, a fluidchemistry, or a chemical composition of the fluid.
 27. The method ofclaim 21, further comprising replacing the sensor probe when at leastone of the filter element or the fluid is changed.
 28. The filterelement of claim 19, wherein the sensor probe comprises a probe portionand an electrical contact, and wherein the probe portion is extends intothe central cavity defined by the disposable ring of filtration media.29. The filter element of claim 28, wherein the sensor probe is mountedto the endplate such that the probe portion extends away from theendplate and into the central cavity.
 30. The filter element of claim28, wherein the electrical contact extends away from the endplate in anopposite direction as the probe portion.
 31. The filter element of claim18, wherein the sensor probe is replaceable when the filter element ischanged.
 32. The filter element of claim 18, wherein the sensor probe isnot recalibrated after replacement.
 33. The filter element of claim 18,further comprising a viscosity sensor configured to assess a viscosityof the fluid.
 34. The filter element of claim 33, wherein the viscositysensor is integral with the sensor probe.
 35. The filter element ofclaim 33, wherein the viscosity sensor is separate from the sensorprobe.
 36. The filter element of claim 18, wherein the sensor probe isfurther configured to enable identification of the filter element. 37.The filter element of claim 18, wherein the sensor probe containsidentifying information about the filter element.